Non-traditional Machining Processes Manufacturing processes can be broadly divided into two groups: primary manufacturing processes : Provide basic shape and size secondary manufacturing processes : Provide final shape and size with tighter control on dimension, surface characteristics Material removal processes once again can be divided into two groups Conventional Machining Processes Non-Traditional Manufacturing Processes or non-conventional Manufacturing processes Conventional Machining Processes mostly remove material in the form of chips by applying forces on the work material with a wedge shaped cutting tool that is harder than the work material under machining condition.

Non-traditional Machining Processes The major characteristics of conventional machining are: • Generally macroscopic chip formation by shear deformation • Material removal takes place due to application of cutting forces – energy domain can be classified as mechanical • Cutting tool is harder than work piece at room temperature as well as under machining conditions Non-conventional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be used for traditional manufacturing processes. The major characteristics of Non-conventional machining are: 1. Material removal may occur with chip formation or even no chip formation may take place. For example in AJM, chips are of microscopic size and in case of Electrochemical machining material removal occurs due to electrochemical dissolution at atomic level.

Non-traditional Machining Processes The major characteristics of Non-conventional machining: 2. In NTM, there may not be a physical tool present. For example in laser jet machining, machining is carried out by laser beam. However in Electrochemical Machining there is a physical tool that is very much required for machining 3. In NTM, the tool need not be harder than the work piece material. For example, in EDM, copper is used as the tool material to machine hardened steels. 4. Mostly NTM processes do not necessarily use mechanical energy to provide material removal. They use different energy domains to provide machining. For example, in USM, AJM, WJM mechanical energy is used to machine material, whereas in ECM electrochemical dissolution constitutes material removal.

Classification of NTM processes classification of NTM processes is carried out depending on the nature of energy used for material removal. 1. Mechanical Processes Abrasive Jet Machining (AJM) Ultrasonic Machining (USM) Water Jet Machining (WJM) Abrasive Water Jet Machining (AWJM) 2. Electrochemical Processes Electrochemical Machining (ECM) Electro Chemical Grinding (ECG) Electro Jet Drilling (EJD) 3. Electro-Thermal Processes Electro-discharge machining (EDM) Laser Jet Machining (LJM) Electron Beam Machining (EBM) 4. Chemical Processes Chemical Milling (CHM) Photochemical Milling (PCM)

Needs for Non Traditional Machining Extremely hard and brittle materials or Difficult to machine materials are difficult to machine by traditional machining processes. When the workpiece is too flexible or slender to support the cutting or grinding forces. When the shape of the part is too complex. Intricate shaped blind hole – e.g. square hole of 15 mmx15 mm with a depth of 30 mm Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20 Machining of composites.